V-fold drawer with filing extrusion

ABSTRACT

A drawer for hanging file folders, which is formed from a drawer subassembly including an elongate drawer plank to which is attached, along a longitudinal edge thereof, an elongate plastic or metal support rail from which hanging file folders may be hung. The drawer subassembly is subsequently folded about a plurality of hinge portions therein which are common to the drawer plank and to the support rail, and a base panel is captured within the drawer subassembly as same is folded to define a drawer including a base panel surrounded by a plurality of vertical walls from which hanging file folders may be hung. The attachment of the support rail to the drawer plank prior to forming the hinge portions in the drawer subassembly and folding same to form the drawer obviates the need to separately attach multiple components of a file folder hanging structure to the drawer walls after the drawer is formed.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under Title 35, U.S.C. §119(e) of U.S. Provisional Application Serial No. 60/291,700, entitled V-FOLD DRAWER WITH FILING EXTRUSION, filed May 17, 2001.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to office furniture systems, and in particular, to a drawer or other container for office furniture systems which is configured to hold hanging file folders therein.

[0004] 2. Description of the Related Art

[0005] Office furniture systems, including desks and workstations, for example, typically include drawers or other containers associated therewith which are configured to hold hanging file folders therein. Hanging file folders generally include a hinged file folder having a plurality of hanger clips attached to the free edges thereof opposite the hinge for hanging the file folders from the hanging structure of a drawer. The hanging structure of the drawer typically includes one or more rails, bars, or other elements which are fastened or clipped onto the upper portions of the drawer walls.

[0006] One method of manufacturing such a drawer includes cutting a groove in one of the side faces of an elongate drawer plank adjacent a lower portion thereof. Then, a plurality of V-shaped miter cuts are made intermediate the ends of the drawer plank to define a plurality of drawer walls therein, which cuts are perpendicular to the long dimension of the drawer plank. Next, a base panel is provided which is fitted within the grooves in the walls of the drawer plank, followed by folding the drawer plank about the miter cuts, and attaching the ends of the drawer plank to one another to thereby form a drawer having a base panel with a plurality of vertical walls therearound. After forming the drawer, the file hanging structure is attached to the upper portions of the drawer walls.

[0007] A problem with such drawers is that, after the drawer is formed as described above, the subsequent attachment of the file hanging structure to the drawer is a time-consuming task, typically requiring a number of individual assembly steps which must be performed by hand. For example, one file hanging structure includes four rail members, which each must be attached to the upper portions of the drawer walls using a plurality of screw fasteners. Other file hanging structures include, for example, a plurality of corner blocks with rail members extending therebetween, or a plurality of individual extruded rail members which are separately attached to each of the drawer walls by fitting protruding tongues thereof within corresponding grooves cut in the top edges of each of the drawer walls.

[0008] What is needed is a drawer for hanging file folders, which drawer may be made according to a process wherein the step of separately attaching the several components of the file hanging structure to the drawer after the drawer is formed is eliminated, such that the drawer is easier and less costly to manufacture.

SUMMARY OF THE INVENTION

[0009] The present invention provides a drawer for hanging file folders, which is formed from a drawer subassembly including an elongate drawer plank to which is attached, along a longitudinal edge thereof, an elongate plastic or metal support rail or extrusion piece from which hanging file folders may be hung. The drawer subassembly is subsequently folded about a plurality of hinge portions therein which are common to the drawer plank and to the support rail, and a base panel is captured within the drawer subassembly as same is folded to define a drawer including a base panel surrounded by a plurality of vertical walls from which hanging file folders may be hung.

[0010] The support rail includes an upper portion having a U-shaped, L-shaped, or any other cross section which may support hanging file folders, and a lower portion thereof may include a longitudinal connecting tongue which is adapted to fit within a corresponding longitudinal groove disposed within the top edge of the drawer plank. The drawer plank additionally includes a groove cut in one of the sides faces thereof adjacent a lower portion of same into which the base panel is captured, and also includes one or more connecting elements associated with the first and second longitudinal ends of the drawer plank.

[0011] To form the drawer, the connecting tongue of the support rail is fitted within the groove along the top edge of the drawer plank, or the support rail is otherwise attached to the drawer plank, in order to form the drawer subassembly. Subsequently, a series of V-shaped miter cuts are made in the drawer subassembly through part of the thicknesses of the each of the drawer plank and the support rail to define the hinge portions of the drawer subassembly. The miter cuts are disposed perpendicular to the long dimension of the drawer subassembly, and, along with the ends of the drawer subassembly, define a plurality of drawer walls therein. Thereafter, the drawer subassembly is folded about the hinge portions with a drawer base panel captured within the grooves in the lower portions of the drawer walls, and the first and second ends of the drawer plank are subsequently attached to one another to form the drawer.

[0012] Advantageously, the attachment of the support rail to the drawer plank prior to making the miter cuts in the drawer subassembly and folding same to form the drawer obviates the need to separately attach multiple components of a file hanging structure to the drawer walls after the drawer is formed, thereby decreasing the difficulty and cost of manufacturing the drawer.

[0013] Additionally, the U-shaped cross section of the upper portion of the support rail allows a plurality of adjacent drawer subassemblies to be pushed together through an automated assembly line in which each of the miter cuts are made in a plurality of drawer subassemblies simultaneously, because the U-shaped cross sections of the support rails contact the edges of adjacent drawer subassemblies in a manner which prevents adjacent drawer subassemblies from overlapping one another when multiple drawer subassemblies are pushed through the assembly line.

[0014] In one form thereof, the present invention provides a drawer for containing hanging file folders, including an elongate drawer plank; an elongate support rail attached to the drawer plank and adapted to support at least one hanging file folder therefrom, the drawer plank and the support rail having a plurality of common hinge portions therein about which the drawer plank and the support rail are folded to define a drawer having a plurality of vertical walls.

[0015] In another form thereof, the present invention provides a method of manufacturing a drawer for hanging file folders, including the steps of providing a drawer subassembly including an elongate drawer plank to which is attached an elongate support rail adapted to support at least one hanging file folder, the drawer subassembly having a long dimension defined between first and second ends; forming a series of hinge portions in the drawer subassembly intermediate the first and second ends, the hinge portions disposed perpendicular to the long dimension of the drawer subassembly; and folding the drawer subassembly about the hinge portions to define a drawer having a plurality of walls.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0017]FIG. 1 is a perspective view of a drawer subassembly in accordance with the present invention, showing an elongate drawer plank and an elongate support rail, the support rail having a lower portion with a longitudinal tongue which is shown being fitted within a corresponding longitudinal groove along an upper edge of the drawer plank;

[0018]FIG. 1A is an end view of the support rail of the drawer subassembly of FIG. 1;

[0019]FIG. 2 is a perspective view of the drawer subassembly of FIG. 1, showing the drawer plank and the support rail attached to one another;

[0020]FIG. 3 is a perspective view of the drawer subassembly of FIG. 2, additionally showing a plurality of miter cuts through part of the thicknesses of the drawer plank and the support rail, the miter cuts defining a plurality of hinge portions in the drawer subassembly;

[0021]FIG. 4 is a schematic, perspective view showing the drawer subassembly of FIG. 3 being folded about the hinge portions and also about a drawer base panel to form a drawer;

[0022]FIG. 5 is a schematic, perspective view of the folded drawer of FIG. 4, further showing a portion of a holding machine or jig for holding the drawer in a square orientation during curing of the adhesive which is used to join the components of the drawer to one another;

[0023]FIG. 6 is a perspective view of the folded drawer of FIG. 5;

[0024]FIG. 7 is a schematic view of a plurality of the drawer subassemblies of FIG. 2 being pushed through an automated assembly line, and further showing a portion of a cutting tool cutting the miter cuts in the drawer subassemblies, wherein the upper portions of the support rails of the drawer subassemblies include an L-shaped cross section;

[0025]FIG. 8 is a schematic view of a plurality of the drawer subassemblies of FIG. 2 being pushed through an automated assembly line, and further showing a portion of a cutting tool cutting the miter cuts in the drawer subassemblies, wherein the upper portions of the support rails of the drawer subassemblies include a U-shaped cross section;

[0026]FIG. 9 is a perspective view of a folded drawer assembly in accordance with another embodiment of the present invention, including a folded drawer subassembly defining three drawer walls to which a separate drawer front is attached;

[0027]FIG. 10 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank, the support rail having a slot for supporting a rod or crossbar from which hanging files may be hung;

[0028]FIG. 11 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank, the support rail having an H-shaped cross section;

[0029]FIG. 12 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank, the support rail having a U-shaped member attached thereto from which hanging files may be hung;

[0030]FIG. 13 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank, the support rail having interior protrusions at the lower ends of parallel rails thereof which engage in a double groove formed along the upper edge of the drawer plank.

[0031]FIG. 14 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank, the support rail having a slot for supporting a rod or crossbar from which hanging files may be hung;

[0032]FIG. 15 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank, the support rail having a T-shaped cross section;

[0033]FIG. 16 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank;

[0034]FIG. 17 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank; the support rail having a slot for supporting a rod or crossbar from which hanging files may be hung;

[0035]FIG. 18 is a sectional view of another embodiment of a drawer subassembly, showing a support rail connected to a drawer plank; the support rail having rail members with internal barbs for engaging the upper edge of the drawer plank; and

[0036]FIG. 19 is a perspective view of a folded drawer assembly in accordance with another embodiment of the present invention, including a folded drawer subassembly defining three drawer walls to which a separate drawer front is attached.

[0037] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate preferred embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

[0038] Referring to FIG. 1, drawer subassembly 20 is shown, which is a component of hanging file folder drawer 22, shown in FIG. 6. Drawer 22 may hold therewithin a plurality of hanging file folders 24, as described further below. Drawer subassembly 20 generally includes drawer plank 26 and support rail 28.

[0039] Drawer plank 26 may be formed of solid wood, pressed particle board, medium density fiber board, or an extruded plastic material, for example. Drawer plank 26 is elongate in overall shape, and includes opposite first and second ends 30, 32; upper and lower edges 34, 36; and inner and outer side faces 38, 40, respectively. A first groove 42 is cut longitudinally along upper edge 34 of drawer plank 26, and a second groove 44 is cut longitudinally in inner side face 38 of drawer plank 26 adjacent lower edge 36 thereof. Connecting elements are associated with each of first and second ends 30, 32 of drawer plank 26, which connecting elements are shown in FIG. 1 as a plurality of dowel rods 46 in first end 30, which may be fitted within a plurality of corresponding holes 48 (FIG. 4), adjacent second end 32 to secure first and second ends 30, 32 together, as explained below.

[0040] Referring to FIGS. 1 and 1A, support rail 28 is also elongate in overall shape, and includes upper portion 50 and lower portion 52. Upper portion 50 includes base 54 and a pair of parallel rail members 56 extending therefrom such that, as shown in FIG. 1A, upper portion 50 defines a U-shaped cross section. Alternatively, base 54 may only include one rail member 56 extending therefrom such that upper portion 50 defines an L-shaped cross section, as shown in FIG. 7. Lower portion 52 of support rail 28 includes longitudinal connecting tongue 58 having a plurality of barbs 60 extending from opposite sides thereof. Support rail 28 may be an extrusion piece formed of metal, or a single piece of extruded plastic material, such as polyvinyl chloride (PVC), for example.

[0041] To attach support rail 28 to drawer plank 26, tongue 58 of support rail 28 is fitted or pressed within groove 42 of drawer plank 26 as shown in FIG. 1, such that barbs 60 of tongue 58 are embedded within drawer plank 26 to firmly and securely attach support rail 28 to drawer plank 26, forming drawer subassembly 20, as shown in FIG. 2.

[0042] Thereafter, a series of hinge portions 62 a-c are formed in drawer subassembly 20. As shown in FIG. 3, such hinge portions are defined by a plurality of V-shaped miter cuts 63 a-c made through a portion of the thicknesses of each of drawer plank 26 and support rail 28 of drawer subassembly 20, wherein miter cuts 63 a-c are cut in a direction perpendicular to the long dimension of drawer subassembly 20. As shown in FIG. 3, three such miter cuts 63 a-c may be made in drawer subassembly 20 to define three hinge portions 62 a-c, and also to define four drawer walls 64 a-d, with first drawer wall 64 a defined between first end 30 of drawer subassembly 20 and first hinge portion 62 a, second drawer wall 64 b defined between first and second hinge portions 62 a,b, third drawer wall 64 c defined between second and third hinge portions 62 b,c, and fourth drawer wall 64 d defined between third hinge portion 62 c and second end 32 of drawer subassembly 20.

[0043] Referring to FIGS. 7 and 8, miter cuts 63 a-c in drawer assembly 20 may be made simultaneously by a cutting tool including a plurality of cutting members, one of which is shown in the form of blade 66. The cutting tool comprises part of an automated assembly line 68 which also includes pushing member 70. Pushing member 70 pushes a group including a plurality of drawer subassemblies 20 through assembly line 68 in a manner in which drawer subassemblies 20 abut against one another such that the support rails 28 of one drawer subassembly 20 abut against lower edge 36 of drawer plank 26 of an adjacent drawer subassembly 20.

[0044] As illustrated in FIG. 7, if support rails 28 of drawer subassemblies 20 have an L-shaped cross section, as described above, it has been found that overlap between the support rail of one drawer subassembly and the bottom edge of an adjacent drawer subassembly may occur when a group of adjacent drawer subassemblies 20 are pushed through automated assembly line 68. If the foregoing overlap occurs, blades 66, rather than making miter cut 63 a-c through only portion of the thickness of drawer subassemblies 20, may cut entirely through one or more drawer subassemblies 20. Therefore, support rails 28 which have such an L-shaped cross section may not be preferred in an automated manufacturing process in which a plurality of drawer subassemblies 20 are pushed in a flat manner adjacent to one another through an automated assembly line 68, as described above.

[0045] Alternatively, referring to FIG. 8, if the support rails 28 of the drawer subassemblies 20 have a U-shaped cross section, as described above, the pair of rail members 56 of upper portion 50 thereof (FIG. 1A) press against an adjacent lower edge 36 of an adjacent drawer subassembly 20 at two points of contact on lower edge 36, such that overlap of adjacent drawer subassemblies 20 is prevented. In this manner, a plurality of drawer subassemblies 20 may be pushed through automated assembly line 68 adjacent to one another without overlapping of adjacent drawer subassemblies 20, such that blades 66 cut through only a portion of the thicknesses of drawer subassemblies 20 to make miter cuts 63 a-c therein.

[0046] Referring to FIG. 4, after miter cuts 63 a-c are made in drawer subassembly 20, drawer subassembly 20 is folded about hinge portions 62 a-c. Additionally, drawer base panel 71 is inserted within grooves 44 of drawer plank 26. After drawer subassembly 20 is thus folded about base panel 71 and about hinge portions 62 a-c to capture base panel 71 therein, dowel rods 46 of first end 30 of drawer plank 26 are fitted within the corresponding holes 48 in second end 32 of drawer plank 26, and a suitable adhesive, such as a hot melt glue, for example, is applied therebetween. An adhesive may also be applied if desired between base panel 71 and grooves 44 in drawer plank 26. Referring to FIG. 5, after drawer subassembly 20 has been thus folded to define drawer 22, drawer 22 is fixedly held in a square orientation by a plurality of holding elements 72 of a holding machine or jig until the adhesive cures.

[0047] After the adhesive cures, drawer 22 may be removed from the holding machine or jig, and suitable drawer hardware such as drawer slide 74 for example, may be attached thereto for slidably attaching drawer 22 to a piece of office furniture. Hanging file folders 24 may be hung within drawer 22 on support rail 28, such that clips 76 of folders 24 are hung on and supported by support rail 28 with folders 24 disposed within interior space 78 of drawer 22.

[0048] As may be appreciated from the foregoing assembly process, the attachment of support rail 28 to drawer plank 26 to form drawer subassembly 20 before hinge portions 62 a-c are formed therein, and also before drawer subassembly 20 is folded to define drawer 22, obviates the additional manufacturing steps of separately connecting the several components of a file hanging structure to drawer 22, thereby decreasing the difficulty and cost of assembling drawer 22.

[0049] However, various details regarding the construction of drawer 22 may vary from that described above. In particular, the shape of support rail 28 may vary widely from the foregoing L-shaped or U-shaped configurations described above. For example, support rail 28 could have a T-shaped or W-shaped cross section, or any other shape adapted to support clips 76 of hanging file folders 24.

[0050] For example, as shown in FIG. 10, support rail 100 includes upper portion 102 having base 104 and a pair of parallel rail members 106 extending therefrom, and lower portion 108 of support rail 100 includes slot 110 for supporting rod or crossbar 112 from which hanging files 24 may also be hung in an orientation perpendicular to any hanging files which are hung from rail members 106. Support rail 100 also includes connecting tongue 58, similar to that of support rail 28, for connecting support rail 100 to drawer plank 26. Referring to FIG. 14, support rail 136 is shown, which is similar to support rail 100, wherein support rail 136 includes a single rail member 106. Referring to FIG. 17, support rail 140 is shown, which is also similar to support rail 100, and includes arms 142 for attaching support rail 140 to drawer plank 26.

[0051] Referring to FIG. 11, support rail 114 includes central portion 116 and parallel rail members 118 defining an H-shaped cross section from which hanging files 24 may be hung, with drawer plank 26 received between rail members 118 for attaching support rail 114 to drawer plank 26. Support rail 150, shown in FIG. 16, is similar to support rail 114, and includes a single elongated rail member 118 to define an upper portion of support rail 150 having an L-shaped cross section.

[0052] Referring to FIG. 12, support rail 120 includes base portion 122 with U-shaped section 124 attached thereto from which hanging files 24 may be hung. Support rail 120 also includes connecting tongue 58, similar to that of support rail 28, for connecting support rail 120 to drawer plank 26. In FIG. 15, support rail 160 is shown, having an upper portion with a T-shaped cross section, and further including connecting tongue 58.

[0053] Also, barbs 60 of tongue 58 of support rail 28 may be eliminated, in favor of the use of fasteners, an interference fit, or an adhesive, for example, to attach support rail 28 to drawer plank 26. In view of the foregoing, groove 42 may be eliminated from upper edge 34 of drawer plank 26. For example, as shown in FIG. 11, support rail 114 is attached to drawer plank 26 by the engagement between upper edge 34 of drawer plank 26 between parallel rail members 118 of support rail 114, and parallel rail members 118 may also include internal barbs 144, shown in FIG. 18, for engaging side faces 38, 40 of drawer plank 26 adjacent upper edge 34 thereof. Also, as shown in FIG. 13, support rail 114 may additionally include a pair of protrusions 126 extending interiorly of the lower ends of parallel rail members 118, which protrusions 126 engage grooves 128 respectively formed in each side face 38, 40 of drawer plank 26 adjacent upper edge 34 thereof.

[0054] Additionally, as shown in FIGS. 9 and 19, drawer subassembly 130 may only include two hinge portions 62 a, 62 b, such that drawer assembly 130, when folded about such hinge portions, defines only three walls or sides 132 a-c of drawer 22, to which a fourth side 132 d may be separately attached, if desired. As shown in FIG. 9, fourth side 132 d may comprise a drawer front including suitable drawer pull hardware, such as pull knob 134. Fourth side 132 d may be attached to the front edges of sides 132 a,c as shown in FIG. 9, or alternatively, as shown in FIG. 19, fourth side 132 d may be attached to the interior faces of sides 132 a,c adjacent the front edges thereof such that fourth side 132 d is captured between sides 132 a,c.

[0055] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. 

What is claimed is:
 1. A drawer for containing hanging file folders, comprising: an elongate drawer plank; an elongate support rail attached to said drawer plank and adapted to support at least one hanging file folder therefrom, said drawer plank and said support rail having a plurality of common hinge portions therein about which said drawer plank and said support rail are folded to define at least three sides of a drawer having a plurality of vertical walls.
 2. The drawer of claim 1, wherein said support rail is an elongate piece of extruded material.
 3. The drawer of claim 1, wherein said drawer plank and said support rail define four sides of said drawer.
 4. The drawer of claim 1, wherein said drawer plank and said support rail define three sides of said drawer, said drawer further including a fourth side attached there to.
 5. The drawer of claim 1, wherein said common hinge portions are defined by miter cuts disposed through a portion of the thicknesses of each of said drawer plank and said support rail.
 6. The drawer of claim 1, wherein said drawer plank includes an upper edge having a longitudinal groove disposed along at least a portion thereof, and said support rail includes a tongue portion extending longitudinally from at least a portion thereof, said tongue portion fitted within said groove to attach said support rail to said drawer plank.
 7. The drawer of claim 6, wherein said tongue portion includes a plurality of barbs thereon for engaging said groove.
 8. The drawer of claim 1, wherein said support rail includes a base portion connected to said drawer plank from which a pair of parallel rail members extend, said base portion and said rail members defining a U-shaped cross section.
 9. The drawer of claim 1, wherein said support rail includes a pair of rail members respectively disposed on opposite sides of an upper edge of said drawer plank to attach said support rail to said drawer plank.
 10. The drawer of claim 9, wherein said rail members include protrusions which engage grooves respectively formed on said opposite sides of said drawer plank adjacent said upper edge.
 11. The drawer of claim 1, wherein said drawer further includes a base panel captured between said plurality of vertical walls.
 12. The drawer of claim 11, wherein each of said walls of said drawer plank includes an interior surface having a groove therein, said base panel is captured within said grooves.
 13. A method of manufacturing a drawer for hanging file folders, comprising: providing a drawer subassembly including an elongate drawer plank to which is attached an elongate support rail adapted to support at least one hanging file folder, the drawer subassembly having a long dimension defined between first and second ends thereof; forming a series of hinge portions in both the drawer plank and the support rail of the drawer subassembly intermediate the first and second ends, the hinge portions disposed perpendicular to the long dimension of the drawer subassembly; and folding the drawer subassembly about the hinge portions to define a drawer having a plurality of walls.
 14. The method of claim 13, including the additional step of attaching a base panel to the drawer subassembly.
 15. The method of claim 13, including the additional step of attaching the first and second ends of the drawer subassembly to one another.
 16. The method of claim 13, wherein said support rail is an elongate piece of extruded material.
 17. The method of claim 13, wherein said folding step includes folding the drawer subassembly about the hinge portions to define a drawer having four walls.
 18. The method of claim 13, wherein said folding step includes folding the drawer subassembly about the hinge portions to define a drawer having three walls.
 19. The method of claim 18, including the additional step of attaching a fourth side to the folded drawer subassembly.
 20. The method of claim 13, wherein the drawer plank includes an upper edge having a longitudinal groove disposed along at least a portion thereof, and the support rail includes a tongue portion extending longitudinally from at least a portion thereof, the tongue portion fitted within the groove to attach the support rail to the drawer plank. 